CN111936287A

CN111936287A - Resin box and method for manufacturing resin box

Info

Publication number: CN111936287A
Application number: CN201980019061.3A
Authority: CN
Inventors: 田渊大辅; 仓田幸; 横村光; 水库由喜; 三根启吾; 山口祐; 松村智行; 吉泽明
Original assignee: Takagi Seiko Co ltd; Honda Motor Co Ltd
Current assignee: Takagi Seiko Co ltd; Honda Motor Co Ltd
Priority date: 2018-03-30
Filing date: 2019-03-11
Publication date: 2020-11-13
Anticipated expiration: 2039-03-11
Also published as: DE112019001712T5; WO2019188212A1; DE112019001712B4; US20210023751A1; CN111936287B; JPWO2019188212A1; JP6957735B2; US11559931B2

Abstract

Provided are a resin box and a method for manufacturing the resin box, wherein the position deviation and deformation of an embedded component are prevented. In a resin box formed by resin injection molding, a part embedded with a resin layer of an embedded plate (119) for mounting accessories is provided with a wall thickness gradually changing part (115) of which the thickness gradually changes from one side to the other side relative to a surface (119a) of the embedded plate (119).

Description

Resin box and method for manufacturing resin box

Technical Field

The present invention relates to a resin tank and a method for manufacturing the resin tank.

Background

Conventionally, a resin case obtained by molding an insertion plate for mounting an auxiliary machine as an insert is known (for example, see patent document 1). Patent document 1 describes: in the blow molding, the annular plate is directly insert-molded into the resin tank main body.

In the case of molding a large closed container such as an automobile fuel tank, a method of embedding a barrier layer in an inner surface and performing injection molding using a thermoplastic synthetic resin is known (for example, see patent document 2). In patent document 2, a large closed container is molded by molding a plurality of split bodies in an open shape by injection molding, and then integrally joining the opening peripheral edges of the split bodies by combining them together and pressing them.

Documents of the prior art

Patent document

Patent document 1: japanese utility model registration No. 2535673

Patent document 2: japanese laid-open patent publication No. 10-157738

Disclosure of Invention

Problems to be solved by the invention

In the technique described in patent document 1, when blow molding, unevenness in wall thickness tends to occur around the annular plate, or inclination of the inserted annular plate or the welding bolt tends to occur, and sufficient molding accuracy cannot be obtained. In this regard, similarly to the injection molding, when the insert plate is provided in the vicinity of the resin injection gate, there are cases where, as in the blow molding, uneven wall thickness occurs around the insert plate, or the plate body or the auxiliary device mounting bolt integrated therewith is inclined. Therefore, it is an object to ensure the quality of the insertion portion.

Further, in the case of injection molding in which a barrier layer is molded in advance and inserted into a mold as in patent document 2, there is also a problem that the gate portion is required to be arranged so as not to cause melting loss or curling due to the flow of high-temperature and high-pressure resin toward the inserted barrier layer.

The present invention has been made in view of the above circumstances, and an object thereof is to provide a resin case and a method for manufacturing the resin case, in which positional displacement or deformation of an inserted member is prevented.

Means for solving the problems

The present specification includes the entire contents of japanese patent application No. 2018-laid-open No. 069518, which was filed 3, 30 and 2018.

The present invention is characterized in that a resin injection molded resin case is provided with a gradually varying thickness portion 115 at a portion where a resin layer of an insertion plate 119 for mounting accessories is inserted, and the gradually varying thickness portion 115 gradually varies in thickness from one side to the other side of the resin layer with respect to a surface 119a of the insertion plate 119.

In the above invention, the wall thickness gradually-varying portion 115 may be provided with: the thickness of the surface 119a of the insertion plate 119 is larger on the upstream side and smaller on the downstream side in the resin flow direction, and the surface 119a of the insertion plate 119 is shifted in a direction away from the upstream inflow portion 115a of the wall thickness gradually-varying portion 115 on the upstream side in a direction perpendicular to the surface 119a of the insertion plate 119.

In the above-described invention, in the resin tank, the resin injection gate portion 91 is provided at a portion surrounded by the insertion plate 119, the stepped portion 113 configured by a shift is formed with respect to the upstream inflow portion 115a, the stepped portion 113 is a seal member joint portion 113 having a lateral wall 113a and a vertical wall 113b extending in a direction perpendicular to the lateral wall 113a, and the seal member joint portion 113 is formed in an open shape as the auxiliary insertion opening 44.

In the above invention, the resin tank may further include a barrier sheet 36b as an insert, the wall thickness gradually-varying portion 115 may have an annular convex portion 114 on an upstream side in a resin flow direction, and an end portion 112 of the opening 110 of the barrier sheet 36b may be accommodated in the annular convex portion 114 in a bent state.

In the above invention, the resin tank may include a removal portion 116 formed by removing the resin from the resin injection gate portion 91, and the wall thickness gradually-varying portion 115 may be provided with: the thickness of the wall on the side closer to the removal portion 116 is larger and the thickness of the wall on the side farther from the removal portion 116 is smaller along the flat surface 119a of the insertion plate 119, and the side surface 119c of the insertion plate 119 is arranged along the wall surface 113b, and the wall surface 113b is arranged along the direction perpendicular to the flat surface 119a of the insertion plate 119.

In the above invention, the removing portion 116 may be formed in an open shape, the insertion plate 119 may be disposed around the removing portion 116, the resin case may be formed with a lateral wall 113a extending in a direction perpendicular to the wall surface 113b, and the removing portion 116 may be disposed on the lateral wall 113 a.

In the method for manufacturing a resin box by resin injection molding, an insertion plate 119 for mounting accessories is positioned and held on a cavity mold 90, and a gradually-varying surface portion 102 is arranged on a core mold 100, and the resin layer 115 is molded so that the thickness of the resin layer gradually varies from one side to the other side with respect to a surface 119a of the insertion plate 119 by the gradually-varying surface portion 102.

In the above invention, the gradually-varying surface portion 102 of the core mold 100 may be provided with: the resin layer on the upstream side is made larger and the resin layer on the downstream side is made smaller in thickness in the resin flow direction with respect to the surface 119a of the insert plate 119, and the insert plate 119 is held by the cavity die 90 such that: the molding surface is shifted in a direction perpendicular to the surface 119a of the insertion plate 119 in a direction away from the molding surface 92 on the upstream side of the insertion plate 119.

In the above invention, the auxiliary device insertion opening 44 may be formed by providing the resin injection gate portion 91 at a portion surrounded by the insertion plate 119, flowing the resin from the resin injection gate portion 91 with a displacement with respect to the upstream mold surface 92, molding a stepped seal member joint portion 113 having a lateral wall 113a and a vertical wall 113b extending in a direction perpendicular to the lateral wall 113a, and cutting the resin layer around the resin injection gate portion 91 while leaving the seal member joint portion 113.

In the above invention, the core mold 100 may be provided with an annular recess 103 on the upstream side of the gradually-varied surface portion 102 in the resin flow direction, and the rib piece 36b provided with the opening 110 may be disposed on the core mold 100 so that the end 112 of the opening 110 is accommodated in the annular recess 103 in a bent state, and the resin may be flowed from the upstream side of the annular recess 103.

Effects of the invention

According to the resin injection-molded resin tank of the present invention, the wall thickness gradually-varying portion that gradually varies from one side to the other side with respect to the thickness of the surface resin layer of the insertion plate for mounting the auxiliary is formed at the portion where the resin layer of the insertion plate for mounting the auxiliary is inserted. According to this configuration, the flow of the resin applied to the insertion plate can be turned by the wall thickness gradually-changing portion to a flow in the surface direction of the insertion plate with respect to the flow of the resin from the resin injection gate portion of the injection molding, and therefore, the insertion plate can be prevented from being positionally displaced or deformed.

In the above invention, the wall thickness gradually-varying portion may be provided with: the surface of the insert plate is displaced in a direction away from an upstream inflow portion of the wall thickness gradually-varying portion located on the upstream side in a direction perpendicular to the surface of the insert plate. According to this configuration, since a pressure difference due to a flow rate difference between both surfaces of the insertion plate according to the shift amount can be generated, the insertion plate can be further prevented from being displaced or deformed.

In the above invention, the resin injection gate portion may be provided at a portion surrounded by the insertion plate, and a stepped portion configured by a shift may be formed with respect to the upstream-side inflow portion, the stepped portion may be a seal member joint portion having a lateral wall and a vertical wall extending in a direction perpendicular to the lateral wall, and the seal member joint portion may be formed in an open shape so as to be an auxiliary insertion opening. With this configuration, the accuracy of alignment between the seal member and the insertion plate portion is improved. In addition, since the auxiliary machine insertion opening is cut out and the resin injection gate portion is also removed, the processing can be simplified.

In the above invention, the resin case may be formed by injecting a barrier sheet as an insert, and the wall thickness gradually-changing portion may have an annular convex portion on an upstream side in a resin flow direction, and an end portion of the opening portion of the barrier sheet may be accommodated in the annular convex portion in a bent state. According to this configuration, even when the barrier sheet and the insert plate are attached to the resin box and injection molding is performed, since the end portion of the opening portion of the barrier sheet is accommodated in the annular convex portion provided on the upstream side in the resin flow direction of the wall thickness gradually-varying portion in a curved state, the barrier sheet can be prevented from being curled up, and the flow of the resin to the insert plate portion is not hindered, so that the quality can be further improved.

In the above invention, the resin tank may include a removal portion formed by removing the resin from the resin injection gate portion, and the wall thickness gradually-varying portion may be provided with: the thickness of the wall on the side close to the removing part is larger and the thickness of the wall on the side far from the removing part is smaller along the flat surface of the embedded plate, the side surface of the embedded plate is arranged along the wall surface, and the wall surface is arranged along the direction vertical to the flat surface of the embedded plate. According to this configuration, a pressure difference is generated due to a difference in flow rate between both surfaces of the insertion plate, and the insertion plate can be further prevented from being displaced or deformed.

In the above invention, the removing portion may be formed in an open shape, the insertion plate may be disposed around the removing portion, the resin case may be formed with a lateral wall extending in a direction perpendicular to the wall surface, and the removing portion may be disposed on the lateral wall. According to this configuration, the removal portion can be provided on the lateral wall, and the resin injection gate portion can be removed at the same time as the opening is cut out, so that the processing can be simplified.

In the method of manufacturing a resin tank by resin injection molding according to the present invention, an insertion plate for mounting an auxiliary machine is positioned and held on a cavity mold, and a gradually varying surface portion for molding a resin layer so that the thickness of the resin layer gradually changes from one side to the other side with respect to the surface of the insertion plate is disposed on the core mold. According to this structure, the flow of the resin applied to the insertion plate can be deflected by the gradually varying surface portion to a flow along the surface direction of the insertion plate with respect to the flow of the resin from the resin injection gate portion of the injection molding, and therefore, the positional deviation or deformation of the insertion plate can be prevented.

In the above invention, the gradually-varying surface portion of the core mold may be provided with: the resin layer on the upstream side has a large wall thickness and the resin layer on the downstream side has a small wall thickness in the resin flow direction with respect to the face of the insert plate, and the insert plate is held on the cavity die such that: the insert plate is displaced in a direction perpendicular to the surface of the insert plate in a direction away from the upstream-side profile of the insert plate. According to this configuration, since the surface of the insertion plate is displaced (separated) in a direction away from the molding surface on the upstream side in the vertical direction, a pressure difference due to a flow rate difference between both surfaces of the insertion plate corresponding to the amount of displacement can be generated, and thus the position displacement or deformation of the insertion plate can be further prevented.

In the above invention, the auxiliary insertion opening may be formed by providing the resin injection gate portion at a position surrounded by the insertion plate, flowing the resin from the resin injection gate portion with a displacement with respect to the upstream mold surface, molding a stepped seal member joint portion having a lateral wall and a vertical wall extending in a direction perpendicular to the lateral wall, and cutting off the resin layer around the resin injection gate portion with the seal member joint portion left. According to this configuration, since the stepped portion having the lateral wall and the vertical wall extending in the direction perpendicular to the lateral wall is used as the seal member joint portion, the accuracy of alignment between the seal member and the insertion plate is also improved. In addition, since the resin injection gate portion is removed simultaneously with the cutting of the auxiliary device insertion opening, the processing can be simplified.

In the above invention, the core mold may be provided with an annular recess on an upstream side of the gradually-varied surface portion in a resin flow direction, and the core mold may be provided with a barrier piece having an opening portion, the barrier piece being disposed so that an end portion of the opening portion is accommodated in the annular recess in a bent state, and the resin may be caused to flow from the upstream side of the annular recess. According to this configuration, even when the barrier sheet and the insert plate are attached to the resin box and injection molding is performed, since the end portion of the opening portion of the barrier sheet is accommodated in the annular recessed portion provided on the upstream side in the resin flow direction of the wall thickness gradually-varying portion in a curved state, the barrier sheet can be prevented from being curled up, and the flow of the resin to the insert plate portion is not hindered, so that the quality can be further improved.

Drawings

Fig. 1 is a perspective view of a front portion of a motorcycle according to an embodiment of the present invention, as viewed from the rear left side.

Fig. 2 is a cross-sectional view of the fuel tank cut at the center of the vehicle width.

Fig. 3 is a cross-sectional view showing the structure of the fuel tank in the thickness direction.

Fig. 4 is a schematic diagram showing a manufacturing process of the fuel tank main body.

Fig. 5 is a main part explanatory view of injection molding of the upper half of the fuel tank main body.

Fig. 6 is a main part explanatory view of injection molding of the lower half of the fuel tank main body.

Fig. 7 is an explanatory view of the lower half of the fuel tank main body as viewed from the inner surface side.

Fig. 8 is an explanatory diagram of a mounting structure of the fuel pump.

Detailed Description

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the description, the directions of the front, rear, left, right, and up and down are the same as the directions of the vehicle body, unless otherwise specified. In the drawings, reference symbol FR denotes the front of the vehicle body, UP denotes the upper of the vehicle body, and LH denotes the left of the vehicle body.

The motorcycle 1 is a vehicle: an engine 10 as a power unit is supported on the vehicle body frame F, a steering system 11 that supports the front wheels 2 so as to be steerable is supported at the front end of the vehicle body frame F so as to be steerable, and a swing arm (not shown) that supports the rear wheels (not shown) is provided on the rear side of the vehicle body frame F. The motorcycle 1 is a saddle-ride type vehicle in which a seat 13 on which a driver sits so as to straddle is provided above the rear portion of a vehicle frame F.

The frame F has: a front upright pipe portion 14 that supports the steering system 11 to be rotatable; a pair of left and right

main frames

15, 15; a lower frame 16; a pair of left and right pivot frames (not shown) extending downward from the rear ends of the

main frames

15, 15 and connected to the rear end of the lower frame 16; a pair of left and right seat frames 17, 17 (not shown, left seat frame) extending rearward from rear end portions of the

main frames

15, 15; and a pair of left and right sub-frames (not shown) extending rearward and upward from the pivot frame and connected to the rear portions of the seat frames 17 and 17.

The engine 10 is located below the main frames 15, and is disposed between the lower frame 16 and the pivot frame (not shown) in the vehicle longitudinal direction.

The seat 13 is disposed above the seat frames 17, 17 and supported by the seat frames 17, 17.

The fuel tank (resin tank) 30 is disposed above the

main frames

15, 15 so as to extend along the main frames 15, and is supported by the

main frames

15, 15. The fuel tank 30 is disposed between the front upright tube portion 14 and the seat 13 in the vehicle front-rear direction. The front end portion of the seat 13 covers the upper surface of the rear portion of the fuel tank 30 from above.

A fuel fill inlet 31 (see fig. 2) is provided in an upper surface of a front portion of the fuel tank 30. A tank cover 32 is attached to the fuel fill inlet 31, and the fuel fill inlet 31 is closed by the tank cover 32.

A tray 33 surrounding the filler opening 31 is attached to the fuel tank 30. The tray 33 is disposed between the lower end of the lid 32 and the upper surface of the fuel tank 30.

The tray 33 is provided with a drain pipe 33a extending downward. The fuel that overflows during refueling or the like is received by the tray 33 and discharged downward from the drain pipe 33 a.

A front mounting bracket (mounting bracket) 37 projecting forward is provided at an upper portion of the front portion of the fuel tank main body 35.

The front portion of the fuel tank main body 35 is fixed to the upper surface of the rear portion of the front upright tube portion 14 by a tank fixing member 39a inserted from above into the front mounting bracket 37.

A pair of right and left rear mounting brackets (mounting brackets) 38L, 38R projecting downward are provided at the lower part of the rear part of the fuel tank main body 35. The

rear mounting brackets

38L, 38R are fixed to the

box brackets

15a, 15a of the

main frames

15, 15 by box fixing members 39b, 39b inserted from the vehicle width direction outer sides, respectively.

Fig. 2 is a cross-sectional view of the fuel tank 30 cut at the center of the vehicle width.

The fuel tank 30 includes a fuel tank main body (tank main body) 35 made of resin, and a barrier sheet layer (barrier layer, barrier sheet) 36 provided on substantially the entire inner surface of the fuel tank main body 35.

The barrier sheet layer 36 is made of a material having a smaller fuel permeability than the material constituting the fuel tank main body 35. The barrier sheet layer 36 prevents fuel such as gasoline stored in the fuel tank 30 from permeating through the fuel tank 30 and leaking to the outside.

The fuel tank body 35 includes a cylindrical injection portion 40 for fuel injection (liquid injection) in an upper portion of the front portion. The cylindrical injection portion 40 is a cylinder extending in the vertical direction, and the upper end portion of the cylindrical injection portion 40 forms the fuel fill inlet 31.

The cylindrical filler 40 is made of the same resin material as that of the fuel tank main body 35, and the cylindrical filler 40 is formed integrally with the fuel tank main body 35.

As shown in fig. 1, a metal mouthpiece 41 is attached to the cylindrical injection portion 40. The mouthpiece 41 is fixed to the upper surface of the fuel tank main body 35 by a plurality of mouthpiece fixing members (fixing members) 42 inserted from above.

The fuel tank body 35 is provided with a pump mounting opening (an auxiliary device insertion opening, an opening for mounting related components) 44 on a lower surface thereof, to which a fuel pump (an auxiliary device, related components) 43 is mounted.

The fuel tank body 35 is divided into an upper half 45 (thermoplastic resin layer, one divided body) constituting an upper portion of the fuel tank body 35 and a lower half 46 (thermoplastic resin layer, the other divided body) constituting a lower portion of the fuel tank body 35. The fuel tank main body 35 is formed in a box shape by joining an upper half body 45 and a lower half body 46.

The upper half body 45 is formed in a box shape with a lower surface opened downward. The peripheral edge of the opening in the lower surface of the upper half body 45 is an upper joining portion (flange portion) 47 joined to the lower half body 46. As shown in fig. 1, the upper joining portion 47 includes a flat surface portion 47a extending substantially horizontally at the rear and a slant surface portion 47b extending forward with a front side higher than a rear side lower than the flat surface portion 47 a.

As shown in fig. 2, the lower half 46 is formed in a box shape with an upper surface opened upward. The peripheral edge portion of the opening in the upper surface of the lower half 46 is a lower joining portion (flange portion) 48 joined to the upper half 45. As shown in fig. 1, the lower joining portion 48 includes: a planar portion 48a parallel to the planar portion 47 a; and a slope portion 48b parallel to the slope portion 47 b. The flat surface portion 47a is joined to the flat surface portion 48a, and the inclined surface portion 47b is joined to the inclined surface portion 48 b.

As shown in fig. 2, the barrier sheet layer 36 includes: an upper barrier sheet 36a (one barrier sheet) bonded to the inner surface of the upper body half 45; and a lower barrier sheet 36b (the other barrier sheet) bonded to the inner surface of the lower half 46.

Fig. 3 is a sectional view showing the structure of the fuel tank 30 in the plate thickness direction.

The fuel tank 30 has a 6-layer structure including a tank body 35, which is a 1-layer resin layer, and a barrier sheet layer 36, which is a 5-layer resin layer.

The barrier sheet layer 36 includes a barrier main body layer 55,

adhesive layers

56, 56 provided on both surfaces of the barrier main body layer 55, and

outer layers

57a, 57b bonded to both sides of the barrier main body layer 55 by the

adhesive layers

56, 56.

For example, the material of the fuel tank body 35 is High Density Polyethylene (HDPE).

The barrier body layer 55 is made of a material that is more resistant to fuel permeation than high density polyethylene. For example, the barrier body layer 55 is made of ethylene-vinyl alcohol copolymer (EVOH).

The

outer layers

57a and 57b are made of the same material as the fuel tank body 35, and are made of high density polyethylene as an example.

The barrier sheet layer 36 is bonded to the inner surface of the tank main body 35 through the outer layer 57a on the tank main body 35 side. Since the spacer sheet layer 36 is bonded to the inner surface of the fuel tank main body 35 via the outer layer 57a made of the same material as the fuel tank main body 35, it has high contact with the fuel tank main body 35 and is firmly bonded to the fuel tank main body 35.

The outer layer 57b of the barrier sheet layer 36 is exposed to the inside of the fuel tank main body 35 to be in contact with the fuel. Thus, direct contact of fuel with barrier body layer 55 is prevented.

Fig. 4 is a schematic diagram illustrating a manufacturing process of the fuel tank main body 35.

Referring to fig. 4, a plurality of materials constituting the barrier sheet layer 36 are supplied to a die 51 for extrusion molding, and a sheet-like molded body 50 is extruded from the die 51.

The molded body 50 is formed along the inner surface of the fuel tank main body 35 by a vacuum forming machine 52. The periphery of the shaped barrier sheet layer 36 is trimmed by a trimming mold (not shown).

The trimmed barrier sheet layer 36 is set in an injection molding die 53 that molds the fuel tank main body 35, and is integrated with the fuel tank main body 35 at the time of injection molding of the fuel tank main body 35. That is, the barrier sheet layer 36 is bonded to the inner surface of the fuel tank main body 35 by insert molding.

Here, the upper-side barrier sheet layer 36a and the lower-side barrier sheet layer 36b are molded separately.

The upper barrier sheet layer 36a is bonded to the upper half body 45 at the time of injection molding of the upper half body 45, and the lower barrier sheet layer 36b is bonded to the lower half body 46 at the time of injection molding of the lower half body 46.

Then, the upper joint surface 47c of the upper joint portion 47 and the lower joint surface 48c of the lower joint portion 48 are melted by heating, and the upper joint surface 47c and the lower joint surface 48c are pressure-bonded together, whereby the upper half body 45 and the lower half body 46 are integrated.

Fig. 5 is a main part explanatory view of injection molding of the upper body half 45.

The upper half 45 of the fuel tank main body 35 is molded by a mold 53A.

Mold 53A includes cavity mold 60 disposed on the upper surface (outer surface) 45a side of upper half 45 and core mold 70 disposed on the lower surface (inner surface) 45b side of upper half 45. A molding space 45c into which the upper half body 45 is molded by filling resin is formed through a space between the cavity mold 60 and the core mold 70.

A gate portion (resin injection gate portion) 61 is formed in the cavity mold 60. The opening 61a of the gate portion 61 is square. The opening 61a of the gate portion 61 is provided at a position where the upper surface 45a of the upper body 45 is molded, and is a so-called direct gate. The gate portion 61 is injected with resin from an injection portion 54 (see fig. 4) of the injection molding machine. The resin having passed through the opening 61a of the gate portion 61 is filled in the molding space 45c of the mold 53A. In the molding space 45c, the farther from the opening 61a of the gate portion 61, the more downstream the resin flows. Hereinafter, the upstream side means the upstream side in the resin flow direction, and the downstream side means the downstream side in the resin flow direction.

A flat plate portion 62 is formed around the opening 61a of the gate portion 61. A flat plate portion 63 that bulges out toward the core mold 70 and narrows the molding space 45c is formed on the downstream side of the flat plate portion 62.

A conical recess (wall surface) 71 is formed in the core mold 70 at a position facing the opening 61a of the gate portion 61. The recessed portion 71 is recessed in a V shape when viewed from the side. The opening width w1 of the opening 71a of the recess 71 is larger than the opening width w0 of the opening 61a of the gate 61. The resin entering through the opening 61a easily enters the inside of the recess 71. The opening width w1 of the recess 71 may be substantially equal to the opening width w0 of the gate portion 61. The resin injected from the gate portion 61 enters the recessed portion 71 and is likely to stay in the recessed portion 71.

An annular recess (annular groove) 72 is formed downstream of the recess 71. The annular recess 72 is recessed relative to the profile of the core 70. The depth h2 of the annular recess 72 is set shallower than the depth h1 of the recess 71. The annular recess 72 is more likely to overflow than the recess 71 when resin flows in. The annular recess 72 is formed to face the boundary position between the flat plate portion 62 and the flat plate portion 63 of the cavity mold 60. The resin is guided by the flat plate portion 62 and the flat plate portion 63 and easily flows into the annular recess 72. The annular recess 72 includes a bottom portion 73 and an inclined portion 74 inclined with respect to the bottom portion 73 and becoming shallower toward the downstream side.

At the time of injection molding of the upper half body 45, the upper barrier sheet layer 36a is provided on the core mold 70.

The upper separator sheet layer 36a is given a shape in advance in accordance with the shape of the lower surface 45b of the upper half body 45. As shown in fig. 2, the upper barrier sheet layer 36a is in the shape of a container whose lower surface is open. The upper separator sheet layer 36a includes: an opening edge portion 36a1 arranged along the upper joining portion 47; an open fuel supply port portion 36a2 formed at the position of the fuel supply port 31; and an opening 80 formed at a position corresponding to the gate portion 61. The opening edge portion 36a1 and the fuel filler port portion 36a2 are bent and joined to each other in a state of being embedded in the resin of the upper half body 45.

As shown in fig. 5, the opening 80 of the upper barrier sheet layer 36a is disposed radially outward of the opening 61a so as to surround the opening 61a of the gate portion 61. Since the opening 80 of the upper barrier sheet layer 36a is located outside the opening 61a of the gate portion 61, contact with the high-temperature and high-pressure resin that has just flowed in from the gate portion 61 can be easily avoided.

The opening 80 includes a curved portion 81 having an annular plate shape. The curved shape portion 81 is curved so as to be away from the main flow portion where the resin flows. The curved shape portion 81 is curved so as to be deeper on the upstream side. The curved portion 81 is received in the annular recess 72 of the core mold 70. The curved portion 81 includes: an end 82 disposed at the bottom 73 of the annular recess 72; and an inclined portion 83 disposed at the inclined portion 74 of the annular recess 72.

After the upper barrier sheet 36a is placed on the core mold 70, the cavity mold 60 and the core mold 70 are closed and locked. Resin is injected from the gate portion 61, and the molding space 45c between the cavity mold 60 and the core mold 70 is filled with resin.

The resin injected into the gate portion 61 flows along the gate portion 61 as shown by an arrow a 1. Since the opening width w1 of the recessed portion 71 is larger than the opening width w0 of the gate portion 61, most of the resin flows into the recessed portion 71. The excess resin flows downstream as indicated by arrow a2 together with the resin overflowing from the recessed portion 71.

The resin flowing into the recessed portion 71 is retained in the recessed portion 71 to form a resin reservoir 84. At the resin reservoir 84, the direction and pressure of the resin flow are uniform. The resin in the recessed portion 71 is guided by a wall surface of the core mold 70 in a V shape in side view, flows as indicated by an arrow a3, and gradually overflows from the recessed portion 71 to move downstream.

By forming the resin reservoir 84 in the recessed portion 71, it is possible to promote flow straightening in the flow direction while discharging air contained in the resin flowing in from the gate portion 61.

On the downstream side of the recessed portion 71, the resin enters the annular recessed portion 72 as indicated by arrow a4, and flows along the upper sheet-blocking layer 36a as indicated by arrow a 5. The upper separator sheet layer 36a includes a curved portion 81 disposed in the annular recess 72, and the resin entering the annular recess 72 flows so as to press the upper separator sheet layer 36a against the core mold 70. The resin can be prevented from spreading in the direction in which the upper barrier sheet layer 36a is peeled off, and the bonding strength between the upper barrier sheet layer 36a and the injected resin can be improved.

The resin easily enters the annular recessed portion 72 regardless of the flow pressure of the resin, and the curved portion 81 of the annular recessed portion 72 is easily and reliably pressed even if the flow pressure of the resin changes. Therefore, the influence of the flow pressure of the resin on the bonding strength of the upper barrier sheet layer 36a can be suppressed, and the quality of the resin molded product in which the upper barrier sheet layer 36a is embedded can be further improved.

The resin reservoir 84 protrudes into the opening 80 of the upper separator sheet layer 36a, and the rectified resin easily flows to the curved portion 81. Since the rectified resin flows into the upper barrier sheet layer 36a, the curved portion 81 can be prevented from peeling off.

When the filling of the resin is finished, the resin is cooled while maintaining a state in which pressure is applied to the resin. When the resin is cooled and solidified, the upper half body 45 corresponding to the shape of the molding space 45c is formed.

An upper barrier sheet layer 36a is embedded and bonded to the upper half body 45.

Corresponding to the recessed portion 71, a cured resin reservoir 84 is formed. The resin reservoir 84 is formed to be thick inside the opening 80 of the upper separator sheet layer 36 a. The resin reservoir 84 can increase the thickness of the portion facing the opening 61a of the gate portion 61, and can reduce the influence of the portion not covered with the upper barrier sheet layer 36 a.

An annular projection 85 is formed corresponding to the annular recess 72. The curved portion 81 of the opening 80 of the upper separator sheet layer 36a is coupled to the annular projection 85 in a housed state.

Resin portion 86 is formed corresponding to gate portion 61.

Cavity mold 60 and core mold 70 are opened, cured upper half 45 is taken out, resin portion 86 cured at gate portion 61 is cut off, and cut-off portion (removed portion) 86a shown in fig. 1 and 2 is formed on upper surface 45a of upper half 45.

Thereby, the welded upper half 45 shown in fig. 4 is formed.

Fig. 6 is a main part explanatory view of injection molding of the lower half 46.

The lower half 46 of the fuel tank body 35 is molded by a mold 53B.

The mold 53B includes: a cavity mold 90 disposed on the lower surface (outer surface) 46a side of the lower half 46; and a core mold 100 disposed on the upper surface (inner surface) 46b side of the lower half 46. The molding space 46c into which the lower half 46 is molded by filling resin is formed by the space between the cavity mold 90 and the core mold 100.

A gate portion (resin injection gate portion) 91 is formed in the cavity mold 90. The opening 91a of the gate portion 91 is circular. The gate portion 91 is disposed in a cut-out portion 120 which is a resin layer cut out when the pump mounting port 44 (see fig. 2) is formed. The gate portion 91 is a so-called direct gate. The gate portion 91 is injected with resin from an injection portion 54 (see fig. 4) of the injection molding machine. The resin having passed through the opening 91a of the gate portion 91 is filled in the molding space 46c of the mold 53B. In the molding space 46c, the opening 91a is located downstream from the gate portion 91.

A flat surface portion (upstream side mold surface) 92 is formed around the opening 91a of the gate portion 91. The flat surface portion 92 is larger than a cutting position 92a at which the pump attachment port 44 (see fig. 2) having an open shape is formed. A step portion 94 having a step difference with respect to the flat portion 92 is formed on the downstream side with respect to the flat portion 92. The step portion 94 includes: a lateral wall 94a formed by a downstream end of the planar portion 92; a vertical wall 94b perpendicular to the lateral wall 94a, and a tapered wall 94c formed at the end portion on the downstream side of the vertical wall 94 b. The resin flowing along the flat surface portion 92 easily moves along the step portion 94, and the flow of the resin easily changes.

A plurality of retaining portions 95 in the form of sunken holes are formed on the downstream side of the step portion 94. An insertion plate 119 provided with a welding bolt 118 is held in the holding portion 95. The insertion plate 119 is a circular plate-shaped member, and has one surface 119b to which four welding bolts 118 are welded at equal intervals on the same circumference, and the other surface 119a formed as a flat surface. By holding the welding bolt 118 by the holding portion 95, the insert plate 119 is disposed in the molding space 46c so as to surround the gate portion 91.

A throttle portion (resistance portion) 96 having a profile bulging shape is provided on the upstream side of the holding portion 95 on the molding space 46c side. The throttle portion 96 forms resistance to the flow of the resin, and reduces the flow rate of the resin.

The insert plate 119 is disposed offset toward the cavity die 90 with respect to the upstream flat surface portion 92. The other surface 119a of the insertion plate 119 is offset in a direction perpendicular to the flat surface portion 92. The resin flowing along the flat surface portion 92 is less likely to directly contact the side portion (side surface) 119c of the insertion plate 119, and the insertion plate 119 is less likely to receive a pressure from the side.

The core mold 100 has a flat surface portion 101 formed at a position facing the opening 91a of the gate portion 91. A guide-shaped surface portion (gradual-change surface portion) 102 is formed on the downstream side of the planar portion 101. The guide surface portion 102 is formed in an inclined shape in which the mold surface bulges toward the cavity mold 90 as it goes toward the downstream side. As shown in fig. 2, the guide surface portion 102 makes the thickness of the resin layer of the lower half 46 larger on the upstream side closer to the gate portion 91 and smaller on the downstream side farther from the gate portion 91.

As shown in fig. 6, the guide surface portion 102 is formed from a position on the upstream side of the stepped portion 94 to a position on the downstream side of the insertion plate 119.

The resin is guided to the cavity mold 90 side by the guide surface portion 102. The resin guided to the cavity mold 90 side easily applies pressure to the face 119a of the insert plate 119.

An annular recess (annular groove) 103 is formed at the upstream end of the guide surface portion 102. The annular recess 103 is recessed relative to the profile of the mandrel 100.

At the time of injection molding of the lower half 46, the lower barrier sheet layer 36b is provided on the core mold 100.

The lower separator sheet layer 36b is given a shape in advance in accordance with the shape of the upper surface 46b of the lower half 46. As shown in fig. 2, the lower barrier sheet layer 36b is in the shape of a container with an open upper surface. The lower separator sheet layer 36b includes an opening-shaped opening edge portion 36b1 disposed along the lower bonding portion 48, and an opening 110 formed at a position corresponding to the gate portion 91. The opening edge portion 36b1 is bent and joined in a state of being embedded in the resin of the lower half 46.

As shown in fig. 6, the opening 110 of the lower separator sheet layer 36b is disposed radially outward of the opening 91a so as to surround the opening 91a of the gate portion 91. Since the opening 110 is located outside the opening 91a of the gate portion 91, the lower barrier sheet layer 36b is easily prevented from coming into contact with the high-temperature and high-pressure resin that has just flowed in from the gate portion 91.

The opening 110 includes a curved portion 111 having an annular plate shape. The curved shape portion 111 is curved so as to be away from the main flow portion where the resin flows. The curved portion 111 has a curved shape corresponding to the profile shape of the guide surface portion 102 of the core mold 100. The curved portion 111 is formed in an inclined shape that bulges toward the cavity mold 90 side as it goes toward the downstream side. The end 112 of the curved portion 111 is curved upward and is accommodated in the annular recess 103 of the core mold 100.

After the lower barrier sheet 36b is placed on the core mold 100, the cavity mold 90 and the core mold 100 are closed and locked. Resin is injected from the gate portion 91, and the molding space 46c between the cavity mold 90 and the core mold 100 is filled with resin.

The resin injected into the gate portion 91 flows along the gate portion 91 as indicated by arrows B1, B2. When the resin flows from the gate portion 91 into the molding space 46c, the resin changes its flow direction as indicated by an arrow B3 and flows into the molding space 46c sandwiched by the flat surface portion 92 of the cavity mold 90 and the flat surface portion 101 of the core mold 100. When passing through the space between the flat surface portion 92 and the flat surface portion 101, the high-temperature and high-pressure resin just flowed in from the gate portion 91 is easily rectified.

On the downstream side of the planar portion 101, as indicated by an arrow B4, the resin enters the annular recess 103 and flows along the lower barrier sheet layer 36B. The lower separator sheet layer 36b includes an end 112 of the curved portion 111 disposed in the annular recess 103, and the resin entering the annular recess 103 flows so as to press the lower separator sheet layer 36b against the core mold 100. The resin can be prevented from spreading in the direction in which the lower barrier sheet layer 36b is peeled off, and the bonding strength between the lower barrier sheet layer 36b and the injected resin can be improved.

In addition, since the resin enters the annular recess 103, the lower separator sheet layer 36b is easily pressed by the resin. In addition, the curved portion 111 disposed on the guide surface portion 102 receives a force from the resin to be pressed toward the core mold 100 as a reaction to guide the resin toward the insertion plate 119. Therefore, even if the flow pressure of the resin changes, the lower barrier sheet layer 36b is easily and reliably pressed, and the influence of the flow pressure of the resin on the bonding strength of the lower barrier sheet layer 36b can be suppressed, and the quality of the resin molded product in which the lower barrier sheet layer 36b is embedded can be further improved.

The guide surface portion 102 and the curved portion 111 are formed in a shape that gradually bulges toward the cavity mold 90 from the upstream side (one side) to the downstream side (the other side) at a position facing the surface 119a of the insertion plate 119, and the thickness of the resin layer is gradually changed. The resin is guided to the cavity mold 90 side and easily flows toward the surface 119a of the insert plate 119 as indicated by arrow B5. Since the direction of the resin flow in the direction of the surface 119a of the insertion plate 119 can be deflected, the insertion plate 119 is easily pressurized from the resin at the surface 119 a. Since the insert plate 119 is pressed toward the cavity mold 90, the insert plate 119 is less likely to float or twist due to the flow of the resin, and positional displacement or deformation of the insert plate 119 can be prevented.

In particular, the insertion plate 119 is disposed downstream of the stepped portion 94 of the cavity die 90, and the surface 119a of the insertion plate 119 is shifted toward the cavity die 90 with respect to the planar portion 92 located upstream. The resin flowing toward the insertion plate 119 flows along the surface 119a of the insertion plate 119 as indicated by arrow B7, or flows between the step portion 94 and the side portion 119c of the insertion plate 119 as indicated by arrow B6, and flows along the surface 119B of the insertion plate 119 as indicated by arrow B8, as indicated by arrow B5. Since a pressure difference due to a difference in flow rate between the

surfaces

119a and 119b on both sides of the insertion plate 119 can be generated according to the amount of displacement, the insertion plate 119 can be easily pressed toward the cavity die 90, and the insertion plate 119 can be prevented from being displaced or deformed.

An annular recess 103 for accommodating the end 112 of the lower separator sheet layer 36b is formed on the upstream side with respect to the position where the insertion plate 119 is disposed. Therefore, the annular recessed portion 103 can prevent the lower separator sheet layer 36b from being rolled up, and the guide surface portion 102 can stably guide the resin toward the insertion plate 119, so that the resin is not prevented from flowing into the insertion plate 119. Therefore, the quality can be further improved with respect to the fitting and bonding of the lower barrier sheet layer 36b and the fitting plate 119.

When the filling of the resin is finished, the resin is cooled while maintaining a state in which pressure is applied to the resin. When the resin is cooled and solidified, the lower half 46 corresponding to the shape of the molding space 46c is formed.

The lower barrier sheet layer 36b is insert bonded to the lower half 46.

An insert plate 119 and a welding bolt 118 are fitted and coupled to the lower half 46.

An annular projection 114 is formed corresponding to the annular recess 103. The end 112 of the opening 110 of the lower separator sheet layer 36b is coupled to the annular projection 114 in a housed state.

A step portion 113 is formed corresponding to the step portion 94, and a lateral wall 113a, a longitudinal wall (wall surface) 113b, and a tapered wall 113c are formed corresponding to the lateral wall 94a, the longitudinal wall 94b, and the tapered wall 94 c.

A wall thickness gradually-changing portion (resin layer) 115 is formed corresponding to the guide surface portion 102. The wall thickness gradually-varying portion 115 includes an upstream inflow portion 115a formed at a position between the guide-shaped surface portion 102 of the core mold 100 and the flat surface portion 92 of the cavity mold 90. In addition, a recess 115b is formed in the wall thickness gradually-changing portion 115 corresponding to the throttle portion 96.

The cutout portion 120 is formed in correspondence with the gate portion 91, the flat portion 92, and the flat portion 101.

Fig. 7 is an explanatory view of the lower half 46 as viewed from the upper surface (inner surface) 46b side.

Referring to fig. 6 and 7, the lower half 46 is cut into a circular shape at a cutting position 92a set between the annular projecting portion 114 and the step portion 113. Thereby, the cut-away portion 120 of the resin having the gate portion 91 is removed.

The lower half 46 is formed with a cut-out portion (removal portion) 116 cut into an open planar shape.

In the lower separator sheet layer 36b, a portion on the side of the end 112 of the curved portion 111 is cut out to form a planar cutout portion (opening) 117 which is cut into an opening larger than the opening 110. The cutout portion 116 and the cutout portion 117 are formed in a coplanar shape, and constitute a pump mounting port (an opening for mounting accessories, an opening for mounting related components) 44.

In the present embodiment, the opening 110 of the lower separator sheet layer 36b is formed by being disposed in the cut-out portion 120 that is cut out. Further, since the cutting is performed at the cut position 92a, which is separated downstream from the end 112 of the opening 110 of the lower separator sheet layer 36b and is not rolled up, the bonding quality of the lower separator sheet layer 36b is improved. In addition, since the resin of the gate portion 91 is removed simultaneously with the cutting process for forming the pump mounting port 44, the process can be simplified.

As described above, the welded lower half 46 shown in fig. 4 is formed.

Fig. 8 is an explanatory diagram of the mounting structure of the fuel pump 43.

The fuel pump 43 is mounted on the lower half 46 of the fuel tank 30 after welding.

The fuel pump 43 includes a cylindrical pump body 43a and a flange 121 provided at a lower portion of the pump body 43 a. Four fixing holes (not shown) are formed in the flange 121, and the welding bolts 118 are inserted through the fixing holes (not shown).

The pump body 43a is inserted into the pump mounting port 44, and the flange portion 121 abuts against the lower surface 46a of the lower half 46.

An O-ring (seal member) 122 is disposed between the pump body 43a and the step (seal member engagement portion) 113 of the lower half 46. The O-ring 122 seals the gap between the lower half 46 and the pump body 43 a. The O-ring 122 is disposed in contact with the lateral wall 113a and the vertical wall 113b of the step portion 113, and is easily positioned. The accuracy of the alignment of the O-ring 122 with respect to the insertion plate 119 is also improved. The O-ring 122 is less displaced from the fuel pump 43 fixed to the insertion plate 119, and the gap is easily and reliably closed.

An abutting portion 121a that abuts against the O-ring 122 from below is formed on the flange portion 121 of the fuel pump 43. Since the O-ring 122 is abutted from three sides by the lateral wall 113a, the vertical wall 113b, and the abutting portion 121a, the deformation control of the O-ring 122 is facilitated, and the sealing is facilitated. By the inclination of the tapered wall 113c, the pump main body portion 43a is easily inserted into the pump mounting port 44.

A flange pressing ring plate 123 is disposed below the flange portion 121. The flange pressing ring plate 123 includes a ring plate-shaped plate portion 123 a. A fixing hole (not shown) is formed in the plate portion 123a, and each welding bolt 118 is inserted through the fixing hole (not shown). A bent sheet-shaped protection portion 123b is integrally formed on the plate portion 123 a. The plate portion 123a presses the flange portion 121 of the fuel pump 43 from below, and the protection portion 123b protects the fuel pump outlet 127 from outside. A fuel pipe (not shown) is connected to the fuel pump outlet 127.

The flange portion 121 of the fuel pump 43, the plate portion 123a of the flange pressing ring plate 123, the flat washer 124, and the lock washer 125 are sequentially attached to the weld bolt 118, and finally the nut 126 is fastened. Thereby, the fuel pump 43 is mounted on the fuel tank 30.

In the present embodiment, the fuel tank 30 made of resin is formed as follows: deformation or rolling of the barrier sheet layer 36 is suppressed, and positional displacement or the like of the insertion plate 119 is suppressed.

As described above, according to the present embodiment to which the present invention is applied, in the resin-made case of resin injection molding, the wall thickness gradually-changing portion 115 in which the thickness of the resin layer gradually changes from one side to the other side with respect to the surface 119a of the insertion plate 119 is formed at the portion where the resin layer of the insertion plate 119 is inserted. Therefore, the direction of the flow of the resin applied to the insertion plate 119 can be diverted to the flow in the surface direction of the insertion plate 119 by the wall thickness gradually-changing portion 115 with respect to the flow of the resin from the gate portion 61 of the injection molding, and therefore, the insertion plate 119 can be prevented from being positionally displaced or deformed.

In the present embodiment, the wall thickness gradually-varying portion 115 is provided such that: the thickness of the surface 119a of the insertion plate 119 is larger on the upstream side and smaller on the downstream side in the resin flow direction, and the surface 119a of the insertion plate 119 is shifted in a direction away from the upstream inflow portion 115a of the wall thickness gradually-varied portion 115 in a direction perpendicular to the surface 119 a. Therefore, a pressure difference due to a difference in flow rate between the

surfaces

119a and 119b on both sides of the insertion plate 119 according to the amount of displacement can be generated, and thus displacement or deformation of the insertion plate 119 can be further prevented.

In the fuel tank 30 of the present embodiment, the gate portion 91 is provided at a portion surrounded by the insertion plate 119, the stepped portion 113 configured by a shift is formed with respect to the upstream inflow portion 115a, the stepped portion 113 is a seal member joining portion 113 having a lateral wall 113a and a vertical wall 113b extending in a direction perpendicular to the lateral wall 113a, and the seal member joining portion 113 is cut open so as to be left as the pump attachment port 44. Therefore, the O-ring 122 is joined to the stepped sealing member joining portion 113, and therefore, the accuracy of positioning with the insertion plate 119 is also improved. In addition, since the cutout portion 120 having the gate portion 91 is removed at the same time as the pump mounting port 44 is cut out, the processing can be simplified.

In the present embodiment, the fuel tank 30 is further injected with the lower separator sheet layer 36b as an insert, and has an annular projection 114 on the upstream side of the thickness gradually-varying portion 115 in the resin flow direction, and the annular projection 114 accommodates the end 112 of the opening 110 of the lower separator sheet layer 36b in a state where the end 112 is bent. Therefore, the lower separator sheet layer 36b can be prevented from being rolled up, and the flow of the resin to the insertion plate 119 is not hindered, so that the quality can be further improved.

In the present embodiment, a cut-out portion (removal portion) 116 from which the resin of the gate portion 91 is removed may be provided, and the wall thickness gradually-varying portion 115 may be provided as follows: the side portion 119c of the insertion plate 119 is disposed along a vertical wall 113b, which is provided along a direction perpendicular to the flat surface 119a of the insertion plate 119, along the flat surface 119a of the insertion plate 119, with the wall thickness on the side close to the cutout portion 116 being large, and the wall thickness on the side far from the cutout portion 116 being small. With this configuration, a pressure difference is generated due to a difference in flow rate between the

surfaces

119a and 119b on both sides of the insertion plate 119, and the insertion plate 119 can be further prevented from being displaced or deformed.

In the present embodiment, the cutout portion 116 may be formed in an open shape, the insertion plate 119 may be disposed around the cutout portion 116, a lateral wall 113a extending in a direction perpendicular to the vertical wall (wall surface) 113b may be formed, and the cutout portion 116 may be disposed on the lateral wall 113 a. According to this configuration, since the cutout portion 116 can be provided in the lateral wall 113a, the gate portion 91 can be removed at the same time as the opening is formed by cutting, and thus the process can be simplified.

As described above, according to the present embodiment to which the present invention is applied, in the method for manufacturing a resin tank by resin injection molding, the insertion plate 119 for mounting a holding accessory is positioned on the cavity mold 90, the guide surface portion 102 for molding the wall thickness gradually-varied portion 115 is arranged on the core mold 100, and the wall thickness gradually-varied portion 115 is a resin layer whose thickness gradually varies from one side to the other side with respect to the surface 119a of the insertion plate 119. Therefore, the direction of the flow of the resin from the gate portion 61 can be deflected by the guide surface portion 102 to a flow in the direction of the surface 119a of the insertion plate 119, and therefore the fuel tank 30 in which the positional deviation or deformation of the insertion plate 119 is prevented can be manufactured.

In the present embodiment, the guide surface portion 102 of the core mold 100 is provided with: the resin layer on the upstream side is thicker and the resin layer on the downstream side is thinner than the surface 119a of the insert plate 119 in the resin flow direction, and the insert plate 119 is held in the cavity die 90 so as to be shifted in a direction away from the surface 119a of the insert plate 119 in a direction perpendicular to the surface 119a, compared to the flat surface portion 92 which is the mold surface on the upstream side of the insert plate 119. Therefore, the surface 119a of the insertion plate 119 is displaced (separated) in a direction away from the upstream flat surface portion 92 in a direction perpendicular thereto, and therefore a pressure difference due to a flow rate difference between the

surfaces

119a and 119b on both sides of the insertion plate 119 corresponding to the displacement can be generated, and thus the positional displacement or deformation of the insertion plate 119 can be further prevented.

In the present embodiment, the gate portion 91 is provided at a portion surrounded by the insertion plate 119, the resin from the gate portion 91 is made to flow while being shifted from the flat surface portion 92, a stepped seal member joint portion 113 having a lateral wall 113a and a vertical wall 113b extending in a direction perpendicular to the lateral wall 113a is formed, and the resin layer around the gate portion 91 is cut away with the seal member joint portion 113 left, thereby forming the pump mounting port 44. Therefore, the O-ring 122 is joined to the stepped sealing member joining portion 113, and therefore, the accuracy of positioning with the insertion plate 119 is also improved. In addition, since the pump mounting port 44 is cut out and the cut-out portion 120 having the gate portion 91 is also removed, the process can be simplified.

In the present embodiment, the core mold 100 is provided with the annular recessed portion 103 on the upstream side in the resin flow direction of the guide surface portion 102, and the lower barrier sheet layer 36b provided with the opening 110 is disposed on the core mold 100 so that the end 112 of the opening 110 is accommodated in the annular recessed portion 103 in a bent state, and the resin flows from the upstream side of the annular recessed portion 103. Therefore, since the end portion 112 of the opening 110 of the lower separator sheet layer 36b is accommodated in a curved state in the annular recess 103 provided on the upstream side in the resin flow direction of the guide surface portion 102 in which the gradually-varying-wall-thickness portion 115 is molded, the lower separator sheet layer 36b can be prevented from being curled up, and the flow of the resin to the insertion plate 119 can be prevented from being obstructed. Therefore, the quality can be further improved.

The above embodiment is merely one embodiment of the present invention, and can be modified and applied arbitrarily without departing from the scope of the present invention.

The resin reservoir portion protruding into the opening 110 may be formed when the lower half 46 is formed, and may be cut out together with the resin reservoir portion.

The step portion 113 in which the portion of the insertion plate 119 is disposed has a lateral wall 113a, a vertical wall 113b perpendicular to the lateral wall 113a, and a tapered wall 113 c. However, the vertical wall 113b may be omitted, and the insertion plate 119 may be disposed in a staggered manner on the stepped portion 113 including the horizontal wall 113a and the tapered wall 113c inclined with respect to the horizontal wall 113 a.

The lateral wall 113a may be inclined with respect to the horizontal direction, and the vertical wall 113b may be inclined with respect to the vertical direction.

Description of the reference symbols

36 b: a barrier sheet;

43: an auxiliary machine;

44: an auxiliary machine insertion opening;

90: a cavity mold;

91: injecting resin into the gate part;

92: a flat portion (a profile on the upstream side);

100: a core mold;

102: a guide-type face (gradual-change face);

103: an annular recess;

112: an end portion;

110: an opening part;

113: a step portion (seal member engagement portion);

113 a: a transverse wall;

113 b: a vertical wall (wall surface);

114: an annular projection;

115: a wall thickness gradient portion (resin layer);

115 a: an upstream inflow section;

116: a removal part;

119: a built-in plate;

119 a: kneading;

119 c: a side surface;

122: and a sealing member.

The claims (modification according to treaty clause 19)

(modified) a resin tank which is a resin injection-molded resin tank, characterized in that,

a thickness-gradually-varying portion (115) is formed at a portion where a resin layer of an insertion plate (119) for mounting an auxiliary is inserted, the thickness-gradually-varying portion (115) gradually varying from one side to the other side of the resin layer with respect to a surface (119a) of the insertion plate (119),

an auxiliary device insertion opening (44) formed in an open shape is provided at an upstream side inflow portion (115a) of the wall thickness gradually-changing portion (115) located on an upstream side in a resin flow direction,

the wall thickness gradually-changing portion (115) is provided: the wall thickness on the side closer to the auxiliary insertion opening (44) on the upstream side in the resin flow direction is larger than the wall thickness on the side farther from the auxiliary insertion opening (44) on the downstream side in the resin flow direction with respect to the surface (119a) of the insertion plate (119), and the wall thickness on the side farther from the auxiliary insertion opening (44) on the downstream side in the resin flow direction is smaller than the wall thickness on the upstream side inflow portion (115a) of the insertion plate (119) in the direction perpendicular to the surface (119a) of the insertion plate (119).

the wall thickness gradually-changing portion (115) is provided: the thickness of the surface (119a) of the insertion plate (119) is larger on the upstream side and smaller on the downstream side in the resin flow direction with respect to the surface (119a) of the insertion plate (119), and the surface (119a) of the insertion plate (119) is shifted in a direction away from the upstream inflow portion (115a) of the wall thickness gradually-changing portion (115) on the upstream side in a direction perpendicular to the surface (119a) of the insertion plate (119),

the resin box is provided with a resin injection gate part (91) at a position surrounded by an insertion plate (119), and a stepped part (113) formed by a shift () is formed with respect to the upstream inflow part (115a), the stepped part (113) is used as a sealing member joint part (113) having a lateral wall (113a) and a vertical wall (113b) extending in a direction perpendicular to the lateral wall (113a), and the sealing member joint part (113) is formed in an open shape as an auxiliary insertion opening (44) while remaining.

(modified) the resin tank according to claim 2,

the resin box is also formed by injecting a barrier sheet (36b) as an insert, and has an annular convex portion (114) on the upstream side of the wall thickness gradually-changing portion (115) in the resin flow direction, and the end portion (112) of the opening portion (110) of the barrier sheet (36b) is housed in the annular convex portion (114) in a bent state.

(modified) the resin tank according to claim 1,

the resin box is provided with a removing part (116) formed by removing the resin of the resin injection gate part (91),

the wall thickness gradually-changing portion (115) is provided: along the flat surface (119a) of the insertion plate (119), the wall thickness on the side close to the removed portion (116) is large, and the wall thickness on the side far from the removed portion (116) is small,

the side surface (119c) of the insertion plate (119) is disposed along a wall surface (113b), and the wall surface (113b) is disposed along a direction perpendicular to a flat surface (119a) of the insertion plate (119).

(modified) the resin tank according to claim 4,

the removal part (116) is formed in an open shape,

the insertion plate (119) is disposed around the removed portion (116),

the resin box is formed with a lateral wall (113a) extending in a direction perpendicular to the wall surface (113b),

the removal portion (116) is disposed on the lateral wall (113 a).

(modified) a method of manufacturing a resin tank, which is a resin injection-molded resin tank, characterized in that,

an insertion plate (119) for mounting accessories is positioned and held on a cavity die (90), a gradually-changing surface part (102) is arranged on a core die (100), the gradually-changing surface part (102) is used for molding a resin layer (115) in a mode that the thickness of the resin layer gradually changes from one side to the other side relative to a surface (119a) of the insertion plate (119),

the gradual-change face portion (102) of the core mold (100) is provided with: the thickness of the resin layer on the upstream side is larger and the thickness of the resin layer on the downstream side is smaller in the resin flow direction with respect to the surface (119a) of the insertion plate (119).

(modified) the method of manufacturing a resin tank according to claim 6, wherein,

-holding the insert plate (119) on the cavity die (90) in such a way that: the molding surface is shifted () in a direction away from the molding surface (92) on the upstream side of the insertion plate (119) in a direction perpendicular to the surface (119a) of the insertion plate (119).

(modified) the method of manufacturing a resin tank according to claim 7, wherein,

a resin injection gate part (91) is provided at a position surrounded by the insert plate (119), the resin from the resin injection gate part (91) is caused to flow with a shift () with respect to the molding surface (92) on the upstream side, a stepped seal member joint part (113) having a lateral wall (113a) and a vertical wall (113b) extending in a direction perpendicular to the lateral wall (113a) is molded, and the resin layer around the resin injection gate part (91) is cut away leaving the seal member joint part (113) to form an auxiliary insertion opening (44).

(modified) the method of manufacturing a resin tank according to any one of claims 6 to 8,

the core mold (100) is provided with an annular recess (103) on the upstream side of the gradual-change-type surface section (102) in the resin flow direction, and a barrier piece (36b) provided with an opening (110) is arranged on the core mold (100) such that an end (112) of the opening (110) is housed in the annular recess (103) in a bent state, and resin flows from the upstream side of the annular recess (103).

(deletion)

Claims

1. A resin tank which is a resin injection molded resin tank characterized in that,

a thickness-gradually-varying portion (115) is formed at a portion where a resin layer of an insertion plate (119) for mounting an auxiliary device is inserted, and the thickness of the thickness-gradually-varying portion (115) varies gradually from one side to the other side of the resin layer with respect to a surface (119a) of the insertion plate (119).

2. A resin tank as defined in claim 1,

the wall thickness gradually-changing portion (115) is provided: the thickness of the surface (119a) of the insertion plate (119) is larger on the upstream side and smaller on the downstream side in the resin flow direction with respect to the surface (119a) of the insertion plate (119), and the surface (119a) of the insertion plate (119) is shifted () in a direction away from the upstream inflow portion (115a) of the wall thickness gradually-changing portion (115) on the upstream side in a direction perpendicular to the surface (119a) of the insertion plate (119).

3. A resin tank as defined in claim 2,

4. The resin tank according to any one of claims 1 to 3,

5. A resin tank as defined in claim 1,

6. A resin tank according to claim 5,

the removal part (116) is formed in an open shape,

the insertion plate (119) is disposed around the removed portion (116),

the removal portion (116) is disposed on the lateral wall (113 a).

7. A method of manufacturing a resin tank, which is a resin injection molded resin tank, characterized in that,

an insertion plate (119) for mounting accessories is positioned and held on a cavity die (90), and a gradually-changing surface section (102) is arranged on a core die (100), and the gradually-changing surface section (102) molds a resin layer (115) in a manner that the thickness of the resin layer gradually changes from one side to the other side relative to a surface (119a) of the insertion plate (119).

8. The method of manufacturing a resin tank as defined in claim 7,

the gradual-change face portion (102) of the core mold (100) is provided with: the thickness of the resin layer on the upstream side is larger and the thickness of the resin layer on the downstream side is smaller in the resin flow direction with respect to the surface (119a) of the insertion plate (119),

9. The method of manufacturing a resin tank as defined in claim 8,

10. The method of manufacturing a resin tank according to any one of claims 7 to 9,